Method and apparatus for improving resolution of objects in a semiconductor wafer

ABSTRACT

A method and apparatus for creating objects on a semiconductor wafer includes a mask/reticle having a substantially uniform pattern of features. The wafer is illuminated through the mask/reticle to create a corresponding uniform pattern of objects on the wafer. Selected objects created by the uniform pattern of features are then utilized to provide desired electrical functions on the integrated circuit. In one embodiment of the invention, the objects are interconnect wires formed by a mask or reticle having a substantially uniform pattern of strips that extends over an area of the integrated circuit. Interconnect wires of different lengths are created by defining endpoints on the strips or by exposing areas on the wafer corresponding to the endpoints of the wires.

FIELD OF THE INVENTION

The present invention relates to photolithographic processing, and in particular to methods of controlling the formation of objects on a semiconductor wafer.

BACKGROUND OF THE INVENTION

Most modem integrated circuits are created by photolithographic techniques whereby selected portions of a silicon wafer are exposed to illumination light. The particular areas that are exposed on the wafer are generally determined by a mask or reticle having opaque and clear areas that block or pass the illumination light.

As the size of the features to be created on the wafer become smaller and smaller, the features can become distorted due to optical effects, such as diffraction or destructive interference of the light passing through the mask or reticle. Another distortion can occur as a result of setting the exposure time/intensity for the wafer. FIG. 1 illustrates a portion of a semiconductor mask or reticle having a number of elements 10 that are relatively widely spaced or isolated from one another. For example, these elements may represent interconnect wires to be created within an integrated circuit. Additionally, the mask or reticle includes a number of elements 12 that are closely grouped with one another. If the exposure of the mask or reticle is set such that the isolated elements 10 are properly imaged on the wafer, then it often happens that the relatively closely grouped elements 12 will be incorrectly exposed. Conversely, if the exposure of the mask or reticle is set such that the closely grouped elements 12 are properly formed on the wafer, then the isolated elements 10 will be incorrectly exposed. In many instances, it is virtually impossible to select an exposure of the mask or reticle that will optimize the formation of closely grouped and isolated circuit elements on a wafer.

SUMMARY OF THE INVENTION

To address the problems discussed above, the present invention is a method for controlling the creation of closely spaced objects on a wafer during photolithographic processing. A mask or reticle has a substantially uniform pattern of features disposed thereon and the exposure of the mask or reticle is chosen such that objects created by the uniform feature pattern is optimized. The uniform pattern of features on the mask/reticle creates a corresponding uniform pattern of objects on a wafer. Selected objects can then be used as desired to provide the desired functionality.

In one embodiment of the invention, the substantially uniform feature pattern comprises a number of uniformly spaced lines that form interconnect wires on an integrated circuit. Interconnect wires of specific lengths are created by terminating the lines at desired points on the mask or reticle. Alternatively, wire of specific length can be created by exposing the wafer at the desired endpoints of the wires.

In another embodiment of the invention, the circuit elements to be created are gate electrodes. A mask or reticle has substantially uniform pattern of strips that create gate electrodes over semiconductor wells. Individual gate electrodes are made by terminating the lines at desired locations either on the mask or reticle itself, or on the wafer.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:

FIG. 1 illustrates a conventional method of forming objects on a wafer with a mask/reticle that includes isolated and closely grouped features;

FIG. 2 illustrates a uniform pattern of features on a mask or reticle that can be used to create interconnect wires in an integrated circuit in accordance with one embodiment of the present invention;

FIG. 3 illustrates one method for creating wires of different lengths on a wafer using the uniform pattern of features shown in FIG. 2;

FIG. 4 is a close up view of an endpoint of a feature as shown in FIG. 3;

FIG. 5 shows how scattering bars can be added to the an endpoint of a feature to improve resolution on a wafer;

FIG. 6 illustrates another method for creating wires of different lengths on a wafer in accordance with another aspect to the present invention;

FIG. 7 illustrates an alternating pattern of P and N wells created on a wafer for creating active devices; and

FIG. 8 illustrates how a uniform pattern of gate electrodes are created over the alternating strips of N and P wells in order to form a number of active devices on the wafer in accordance with another aspect of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

To eliminate the problems associated with selecting an exposure duration/intensity of a mask/reticle that includes both isolated and closely spaced features, the present invention utilizes a substantially uniform pattern of features on a mask or reticle to create a corresponding uniform pattern of objects on a wafer. Because each of the features is relatively uniformly spaced, each object created from a feature is formed in the same way on the surface of the wafer due to the same exposure conditions of the mask or reticle.

FIG. 2 shows a portion of a mask or reticle 20 having a substantially uniform pattern of features 22 that create a corresponding uniform pattern of objects on a semiconductor wafer. In the example shown, the features are strips that create interconnect wires on the wafer.

Interconnect wires of various lengths can be made by making endpoints on the strips on the mask or reticle as desired. For example, FIG. 3 shows a mask or reticle that creates a short wire 30 by placing endpoints 32 and 34 in the feature 36. A longer wire 38 is created by placing endpoints 40, 42 in a feature 44, etc.

In order to route signals to desired locations within an integrated circuit, two patterns of interconnect are formed on different layers within the wafer using two or more masks/reticles of the type shown in FIGS. 2 and 3 and that are oriented at any angle with respect to each other, usually at 90°. Individual interconnect wires in the two layers are connected together with vias in order to direct signals to desired locations within an integrated circuit.

FIG. 4 shows in detail an endpoint 46 that is created in a feature of a mask/reticle. Depending upon the size of the interconnect wires to be created, the endpoint 46 may be created by placing a break somewhere along the length of an individual strip on the mask/reticle.. However, in many instances, the pattern on the wafer created by the endpoint 46 may become distorted when the features are closely spaced on the mask/reticle. Therefore, it may be advisable to place one or more scattering bars 50 adjacent the endpoint as shown in FIG. 5. As is well known to those of ordinary skill in the art, the use of scattering bars enhances the resolvability of objects created on the wafer. The scattering bars themselves are generally too small to be resolved on the wafer.

Even with some of the features in the mask/reticle 28 shown in FIG. 3 having a number endpoints along their length, the features are still similar enough so that the objects on the wafer will be uniformly formed when the mask/reticle is exposed.

By using a mask/reticle of the type shown in FIGS. 2 and 3, it will be appreciated that more interconnect wires are formed on the wafer than may be necessary. The unused wires can be connected to a common power or ground source for shielding and inductance reduction or could be left uncoupled in the integrated circuit.

FIG. 6 shows a mask or reticle 60 having a uniform pattern of features 62 without endpoints in order to create a corresponding uniform pattern of objects on a semiconductor wafer. To create wires of different lengths, another mask/reticle 64 can be used having areas 66 that are placed at specific locations in order to expose the wafer at the location of the desired endpoints of an interconnect wire. The advantage of using the system shown in FIG. 6 is that the same mask/reticle 60 can be used for a number of different integrated circuits and is not specific to any one circuit design.

In yet alternative embodiment of the invention, the endpoints of the interconnect wires can be created using a direct writing laser or other exposure source on the wafer itself. Because the endpoints of the wires are relatively few compared to the size of the chip, direct writing each of the endpoints of the objects will greatly speed the direct writing of wires.

The present invention is not limited to creating interconnect wires on an integrated circuit. For example, the present invention can also be used in creating gate electrodes for active semiconductor devices. FIG. 7 shows a portion of an integrated circuit wafer 90 including alternating P wells 92 and N wells 94 that are used to make transistors on the semiconductor wafer. A pattern of gate electrodes can be formed over the N and P wells 92, 94 using a mask or reticle having a uniform pattern of features 96 as shown in FIG. 8. The features comprise a set of substantially uniform parallel strips that extend over the area of the integrated circuit. Individual gates can be formed by making endpoints along the length of a strip on the mask/reticle or by selectively exposing an area of the wafer at the location of the desired endpoint of a gate created by the features. The endpoints in the features 96 can be placed such that a gate is formed over a single well or over multiple wells in accordance with the electrical characteristics of the transistor to be created. By placing rows of features 96 on the mask/reticle, each of the gates is formed in a similar manner due to the same exposure conditions of the mask/reticle.

Although the present invention has been described with respect to interconnect wires and gate electrodes on a semiconductor wafer, it would be appreciated that the technique can be applied to forming other devices on an integrated circuit. By exposing a wafer with a mask or reticle including a uniform pattern of features to be created and selectively coupling or enabling particular devices created from the uniform patters of features at desired locations on the wafer, the distortions normally associated with exposing isolated and grouped features on a mask/reticle are reduced or eliminated. Furthermore, it is not necessary that the uniform pattern of features on the mask/reticle extend over the entire area of the integrated circuit. For example, the mask/reticle may include a pattern of features that creates corresponding objects in only a portion of the integrated circuit area. However, the pattern of features on the mask/reticle should have substantially identical exposure characteristics. 

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:
 1. A method for lithographically forming objects on a surface of a semiconductor wafer, comprising the acts of: providing a mask/reticle having a substantially uniform pattern of features; exposing the surface through the mask/reticle to create a substantially uniform pattern of objects corresponding to the substantially uniform pattern of features on the mask/reticle; and selectively utilizing some of the objects created on the surface of the semiconductor wafer; wherein the objects created on the surface of the semiconductor wafer are interconnect wires.
 2. A method for lithographically forming objects on a surface of a semiconductor wafer, comprising the acts of: providing a mask/reticle having a substantially uniform pattern of features; exposing the surface through the mask/reticle to create a substantially uniform pattern of objects corresponding to the substantially uniform pattern of features on the mask/reticle; and selectively utilizing some of the objects created on the surface of the semiconductor wafer; wherein the objects created on the surface of the semiconductor wafer are transistor electrodes.
 3. A method for lithographically forming objects on a surface of a semiconductor wafer, comprising the acts of: providing a mask/reticle having a substantially uniform pattern of features; exposing the surface through the mask/reticle to create a substantially uniform pattern of objects corresponding to the substantially uniform pattern of features on the mask/reticle; selectively utilizing some of the objects created on the surface of the semiconductor wafer; and connecting unused objects on the surface to a common power or ground source.
 4. A method of forming interconnect wires on a surface of a semiconductor substrate, comprising: exposing the surface of a semiconductor substrate with a mask/reticle having a substantially uniform pattern of strips that extend over the area of the substrate, the strips having end points defined along their length; and selectively using some of the interconnect wires created on the semiconductor substrate.
 5. A method of creating interconnect wires on a semiconductor wafer, comprising: exposing the wafer with a first mask/reticle having a substantially uniform pattern of aligned strips, each strip defining an interconnect wire on the wafer; exposing the wafer with a second mask/reticle having a substantially uniform pattern of aligned strips, each strip defining an interconnect wire on the wafer, wherein the strips of the first and second mask/reticles are formed on different layers and oriented at an angle with respect to each other; and selectively coupling interconnect wires created from the first mask/reticle and the second mask/reticle with vias. 